System and method for performing surgical procedures with a reusable instrument module

ABSTRACT

A surgical instrument includes an outer housing shell defining a cavity. The outer housing shell defines an upper outer housing half and a lower outer housing half. The upper outer housing half defines a longitudinal axis. An instrument module is selectively insertable into the cavity of the outer housing shell. The instrument module includes an inner housing shell, at least one motor disposed within the inner housing shell, a control board being in electrical communication with the at least one motor, and an energy source being in electrical communication with the at least one motor and the control board. The instrument module is inserted into the cavity of the outer housing shell in such a manner that the operative axis of the at least one motor is substantially parallel to the longitudinal axis of the upper outer housing half

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation Application of U.S. patentapplication Ser. No. 14/551,321, filed Nov. 24, 2014, which is aContinuation Application of U.S. patent application Ser. No. 13/719,344(now U.S. Pat. No. 8,894,647), filed on Dec. 19, 2012, which claims thebenefit of and priority to U.S. Provisional Patent Application Ser. No.61/586,201, filed on Jan. 13, 2012, the entire contents of each of whichare incorporated by reference herein.

The present application relates to U.S. patent application Ser. No.13/719,377, titled SYSTEM AND METHOD FOR PERFORMING SURGICAL PROCEDURESWITH A REUSABLE INSTRUMENT MODULE, filed Dec. 19, 2012, the entirecontents of which are incorporated by reference herein.

BACKGROUND

1. Technical Field

The present disclosure relates generally to the field of reposable orreusable surgical instruments. In particular, the disclosure relates toinstruments having separable and replaceable components to provideclean, sterile or refurbished surfaces in each instance of use.

2. Background of Related Art

One type of surgical device is a linear clamping, cutting and staplingdevice. Such a device may be employed in a surgical procedure to resecta cancerous or anomalous tissue from a gastro-intestinal tract.Conventional linear clamping, cutting and stapling instruments include apistol grip-styled structure having an elongated shaft and distalportion. The distal portion includes a pair of scissors-styled grippingelements, which clamp the open ends of the colon closed. In this device,one of the two scissors-styled gripping elements, such as the anvilportion, moves or pivots relative to the overall structure, whereas theother gripping element remains fixed relative to the overall structure.The actuation of this scissoring device (the pivoting of the anvilportion) is controlled by a grip trigger maintained in the handle.

In addition to the scissoring device, the distal portion also includes astapling mechanism. The fixed gripping element of the scissoringmechanism includes a staple cartridge receiving region and a mechanismfor driving the staples up through the clamped end of the tissue againstthe anvil portion, thereby sealing the previously opened end. Thescissoring elements may be integrally formed with the shaft or may bedetachable such that various scissoring and stapling elements may beinterchangeable.

A number of surgical device manufacturers have developed product lineswith proprietary drive systems for operating and/or manipulating suchsurgical device. In many instances, such surgical device furtherincludes a handle assembly, which is reusable, and a disposable endeffector or the like that is selectively connected to the handleassembly prior to use and then disconnected from the end effectorfollowing use in order to be disposed of or in some instances sterilizedfor re-use.

Surgical devices that are reposable, or reusable for multipleprocedures, reduce the instrumentation costs per procedure. Providing areusable surgical device, however, presents various challenges. Forexample, the complexity of a surgical device tends to result in fairlylabor intensive cleaning procedures to prepare the surgical device forsubsequent use. Improper cleaning may result in dangerous contaminationbeing introduced into the surgical site. Also, some reusable surgicaldevices have removable and replaceable components to provide cleansurfaces for each use. Many of these surgical devices require arduousdisassembly and reassembly procedures that require extensive training,and may discourage use of the surgical device.

SUMMARY

According to an embodiment of the present disclosure, a surgicalinstrument is provided. The surgical instrument includes an outerhousing shell defining a cavity, the outer housing shell defining anupper outer housing half and a lower outer housing half, wherein theupper outer housing half defines a longitudinal axis and an instrumentmodule selectively insertable into the cavity of the outer housingshell. The instrument module includes an inner housing shell, at leastone motor disposed within the inner housing shell, the at least onemotor including a drive shaft defining an operative axis of rotation, acontrol board disposed within the inner housing and being in electricalcommunication with the at least one motor and an energy source disposedwithin the inner housing and being in electrical communication with theat least one motor and the control board. The instrument module isinserted into the cavity of the outer housing shell in such a mannerthat the operative axis of the at least one motor is substantiallyparallel to the longitudinal axis of the upper outer housing half

Additionally, the outer housing shell may be devoid of movable switches.

In an exemplary embodiment, the upper outer housing half and the lowerouter housing half combine to form a pistol-grip configuration.

The outer housing shell may be at least partially translucent or atleast partially transparent.

In another exemplary embodiment, the upper outer housing half includesat least one speaker for providing feedback information related totissue parameters and surgical instrument parameters measured during asurgical procedure.

In yet another exemplary embodiment, the upper outer housing halfincludes at least one viewing window for viewing a display screendisposed therein displaying information related to tissue parameters andsurgical instrument parameters measured during a surgical procedure. Thedisplay screen includes at least one of numerical indicators and colorindicators.

Moreover, the control board electrically communicates with at least oneprocessor for enabling flow of electrosurgical energy between the energysource and the at least one motor.

In yet another exemplary embodiment, the lower outer housing halfincludes an instrument shell cover hingedly connected thereto, theinstrument shell cover configured to swivel into place after theinstrument module is inserted into the cavity of the outer housingshell. Alternatively, an instrument shell cover is attached to at leasta portion of the lower outer housing half, such that the upper and lowerouter housing halves attach to the instrument shell cover to form asecure connection.

The outer housing shell may define at least one opening formed in adistal surface thereof for receiving the drive shaft therethrough whenthe instrument module is fully disposed in the outer housing shell.

A seal may be supported in the opening formed in the distal surface ofthe outer housing shell, wherein the seal forms a fluid-tight sealbetween the outer housing shell and the drive shaft.

The instrument module may include a plurality of motors each including adrive shaft extending therefrom. The outer housing shell may define aplurality of openings formed in a distal surface thereof for receiving arespective drive shaft therethrough when the instrument module is fullydisposed in the outer housing shell. A seal may be supported in eachopening formed in the distal surface of the outer housing shell, whereineach seal forms a fluid-tight seal between the outer housing shell andthe respective drive shaft.

In another exemplary embodiment, a method of performing a surgicalprocedure is presented. The method includes the steps of providing anouter housing shell defining a cavity, the outer housing shell definingan upper outer housing half and a lower outer housing half, wherein theupper outer housing half defines a longitudinal axis and selectivelyinserting an instrument module into the cavity of the outer housingshell. The instrument module includes an inner housing shell, at leastone motor disposed within the inner housing shell, the at least onemotor including a drive shaft defining an operative axis of rotation, acontrol board disposed within the inner housing and being in electricalcommunication with the at least one motor and an energy source disposedwithin the inner housing and being in electrical communication with theat least one motor and the control board. The instrument module isinserted into the cavity of the outer housing shell in such a mannerthat the operative axis of the at least one motor is substantiallyparallel to the longitudinal axis of the upper outer housing half.

The outer housing shell may be at least partially translucent or atleast partially transparent.

The outer housing shell may define at least one opening formed in adistal surface thereof for receiving the drive shaft therethrough whenthe instrument module is fully disposed in the outer housing shell.

A seal may be supported in the opening formed in the distal surface ofthe outer housing shell, wherein the seal forms a fluid-tight sealbetween the outer housing shell and the drive shaft.

The instrument module may include a plurality of motors each including adrive shaft extending therefrom. The outer housing shell may define aplurality of openings formed in a distal surface thereof for receiving arespective drive shaft therethrough when the instrument module is fullydisposed in the outer housing shell. A seal may be supported in eachopening formed in the distal surface of the outer housing shell, whereineach seal forms a fluid-tight seal between the outer housing shell andthe respective drive shaft.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the disclosureand, together with a general description of the disclosure given above,and the detailed description of the embodiment(s) given below, serve toexplain the principles of the disclosure, wherein:

FIGS. 1A and 1B illustrate perspective views of a reusable surgicalinstrument module, in accordance with the present disclosure;

FIG. 2 illustrates a reusable surgical instrument module inserted intoan outer housing shell having a hinged instrument cover shell, inaccordance with an embodiment of the present disclosure;

FIG. 3 illustrates a reusable surgical instrument module inserted intoan outer housing shell having a snapable instrument cover shell, inaccordance with another embodiment of the present disclosure; and

FIG. 4 is an enlarged, schematic, longitudinal cross-sectional viewillustrating the reusable surgical instrument module inserted into theouter housing shell, and showing seals disposed about drive shafts ofthe reusable surgical instrument module.

DETAILED DESCRIPTION

Embodiments of the presently disclosed apparatus will now be describedin detail with reference to the drawings, in which like referencenumerals designate identical or corresponding elements in each of theseveral views. As used herein, the term “distal” refers to that portionof the tool, or component thereof which is further from the user whilethe term “proximal” refers to that portion of the tool or componentthereof which is closer to the user.

Referring to FIGS. 1A and 1B, perspective views of a reusable surgicalinstrument module 110 are illustrated, in accordance with the presentdisclosure.

Instrument module 110 defines an upper instrument module half 110A and alower instrument module half 110B, upper instrument module half 110Adefining a longitudinal axis “B.” Instrument module 110 also includes aninner housing shell 111 for incorporating a plurality of componentstherein, as described below.

Upper instrument module half 110A includes at least one motor 140, aswell as a display screen 160. At least one motor 140 is disposed withininner housing shell 111. A distal end 102 of upper instrument modulehalf 110A is configured to receive an end effector assembly (not shown).End effector assembly may be at least one of jaw members, a clipapplier, vessel sealing devices, circular stapling devices, dissectors,retractors, cutters, graspers, and drills.

Lower instrument module half 110B includes a battery 120 (or energysource) and at least one control board 130. Battery 120 and at least onecontrol board 130 are disposed within inner housing shell 111. Lowerinstrument module half 110B is configured to be gripped by a user, suchas surgeon, during a surgical procedure. Additionally, upper instrumentmodule half 110A and lower instrument module half 110B may combine toform a substantially L-shaped or pistol-grip configuration.

At least one control board 130 is connected, on the one hand,electrically to battery 120, and, on the other hand, to at least onemotor 140. To this end, electric contacts (not shown) are provided on anupper side of battery 120 for establishing an electric connection withat least one control board 130. Additionally, at least one control board130 electrically communicates with at least one processor (not shown)for enabling flow of electrosurgical energy between the energy source(e.g., battery 120) and each motor 140.

Each motor 140 is configured to include, for instance, a drive shaft142. Drive shaft 142 defines an operative axis of rotation “B.” Eachmotor 140 is configured to actuate a function or operation of an endeffector assembly (not shown), including but not limited to,articulating, rotating, closing of the jaw members, ejecting fasteners,cutting, and the like.

Instrument module 110 may include a speaker 150 (see FIG. 1B), at aproximal end 104 thereof, for providing feedback information related totissue parameters and surgical instrument parameters measured during asurgical procedure. Speaker 150 may be used to provide audible feedback.Audible feedback may be used in conjunction with or in lieu of thevisual outputs.

Instrument module 110 may include display screen 160 disposed thereindisplaying information related to tissue parameters and surgicalinstrument parameters measured during a surgical procedure. Displayscreen 160 may be configured to provide the surgeon with a variety ofsuitable output information. Display screen 160 may include at least oneof numerical indicators and color indicators.

Instrument module 110 may also include a clamp button 170 and a returnbutton 180. Clamp button 170 may be configured to actuate an endeffector assembly (not shown) connected to distal end 102 of instrumentmodule 110 to a first position. End effector assembly may be a pair ofjaw members for clamping tissue in the first position. Return button 180may be configured to return the jaw members to an open, unclampedposition (or second position).

Referring to FIG. 2, a method of inserting a reusable surgicalinstrument module 110 into an outer housing shell 280 having a hingedinstrument cover shell 290, in accordance with an embodiment of thepresent disclosure is presented.

Outer housing shell 280 defines a cavity 282 therein. Outer housingshell 280 defines an upper outer housing half 280A and a lower outerhousing half 280B. Upper outer housing half 280A defines a longitudinalaxis “A” extending therethrough. Outer housing shell 280 also includesinstrument shell cover 290 connected to lower outer housing half 280Bvia a hinged connection 292. Instrument shell cover 290 may rotate orpivot in direction “C” after instrument module 110 has been fullyinserted into outer housing shell 280, as described below. In accordancewith an embodiment of the present disclosure, outer housing shell 280may be devoid of movable switches.

In operation or use, instrument module 110 is inserted into cavity 282of outer housing shell 280 in such a manner that operative axis “B” ofat least one motor 140 is substantially parallel to longitudinal axis“A” of upper outer housing half 280A. Stated differently, instrumentmodule 110 is configured to be inserted into reusable outer housingshell 280, such that instrument module 110 is inserted and extractedalong an axis of operation of at least one motor 140 or alonglongitudinal axis “B.” Upper instrument module half 110A is configuredto underlie or nest upper outer housing half 280A, whereas lowerinstrument module half 110B is configured to underlie or nest lowerouter housing half 280B. Once instrument shell 110 is fully insertedinto outer housing shell 280, instrument shell cover 290 is rotated, indirection “C,” in order to create a secure seal with outer housing shell280.

Following a surgical procedure, instrument shell cover 290 is opened andinstrument module 110 is withdrawn from or removed from cavity 282 ofouter housing shell 280 such that outer housing shell 280 and shellcover 290 may be cleaned in accordance with methods and procedures knownin the art, for example, sterilizing, autoclaving, steam cleaning,wiping with cleaning products/solvents and the like. Thus, outer housingshell 280 and shell cover 290 may be cleaned or sterilized withoutcompromising instrument module 110 inserted therein. Once cleaning orsterilization has been completed, instrument module 110 may bere-introduced into cavity 282 of outer housing shell 280 prior toperforming a further surgical procedure.

Referring to FIG. 3, a method of inserting a reusable surgicalinstrument module 110 into an outer housing shell 380 having a snapableinstrument cover shell 390, in accordance with another embodiment of thepresent disclosure is illustrated.

Outer housing shell 380 defines a cavity 382 therein. Outer housingshell 380 defines an upper outer housing half 380A and a lower outerhousing half 380B. Upper outer housing half 380A defines a longitudinalaxis “D” extending therethrough. Lower outer housing half 380B of outerhousing shell 380 may connect or attach to instrument shell cover 390via, for example, a snapable mechanism including fasteners (not shown).Additionally, a clear viewing window 385 may be constructed so that itoverlays a display screen (e.g., as described above with reference toFIGS. 1A and 1B). Viewing window 385 is designed for viewing the displayscreen disposed therein displaying information related to tissueparameters and surgical instrument parameters measured during a surgicalprocedure.

In accordance with the present disclosure, it is contemplated that outerhousing shell 380 (as well as outer housing shells 180, 280) may befabricated from a translucent or transparent material, such as, forexample, a polycarbonate resin thermoplastic. As so constructed, indiciafrom display screen 160 of instrument module 110 or the like. It isfurther contemplated that at least a portion of outer housing shell 380may be translucent or transparent.

In operation or use, instrument module 110 is inserted into cavity 382of outer housing shell 380 in such a manner that operative axis “E” ofat least one motor 140 (or of at least one drive shaft 142) issubstantially parallel to longitudinal axis “D” of upper outer housinghalf 110A. Stated differently, instrument module 110 is configured to beinserted into instrument outer housing shell 380, such that instrumentmodule 110 is inserted and extracted along an axis of operation of atleast one motor 140, or along longitudinal axis “E.” Upper instrumentmodule half 110A is configured to underlie or nest upper outer housinghalf 380A, whereas lower instrument module half 110B is configured tounderlie or nest lower outer housing half 380B. Once instrument shellcover 390 is attached to a portion of lower outer housing half 380B,instrument module 110 is inserted into outer housing shell 380 such thatupper outer housing half 380A and the remaining portion of the lowerouter housing half 380B lock or secure or seal with instrument shellcover 390 along connection region 395.

Following a surgical procedure, instrument shell cover 390 is withdrawnor unsnapped from lower outer housing half 380B (at connection region395) and instrument module 110 is withdrawn from or removed from cavity382 of outer housing shell 380 such that outer housing shell 380 andshell cover 390 may be cleaned in accordance with methods and proceduresknown in the art. Thus, outer housing shell 380 may be cleaned orsterilized without compromising instrument module 110 inserted therein.Once cleaning or sterilization has been completed, instrument module 110may be re-introduced into cavity 382 of outer housing shell 380 prior toperforming a further surgical procedure.

Turning now to FIG. 4, in accordance with the present disclosure, it iscontemplated that outer housing shell 280, 380 may define a plurality ofapertures 150 through which each drive shaft 142 passes. A seal 152 isprovided in each aperture 150 and is supported therein so as to remainwith outer housing shell 280, 380 during insertion/retraction ofinstrument module 110 therein/therefrom. Seals 152 may take the form ofO-rings or the like, and may be constructed from a resilient, polymericmaterial, such as, for example, rubber. Seals 152 are configured anddimensioned to establish a fluid-tight seal between outer housing shell280, 380 and drive shafts 142. Additionally, seals 152 are configuredand dimensioned to permit drive shafts 142 to rotate. In use, when shellcovers 290, 390 are closed against respective outer housing shells 280,380, a force is exerted against instrument module 110, substantiallyalong or in direction “B”, to thereby press a distal surface of upperinstrument module half 110A against seals 152 and establish afluid-tight seal against an outer surface of drive shafts 142.

While several embodiments of the disclosure have been shown in thedrawings, it is not intended that the disclosure be limited thereto, asit is intended that the disclosure be as broad in scope as the art willallow and that the specification be read likewise. Therefore, the abovedescription should not be construed as limiting, but merely asexemplifications of presently disclosed embodiments. Thus the scope ofthe embodiments should be determined by the appended claims and theirlegal equivalents, rather than by the examples given.

1. (canceled)
 2. A method of assembling a surgical instrument, themethod comprising: inserting a proximal end of an instrument module intoa proximal portion of an outer housing shell; and approximating theproximal portion of the outer housing shell and a distal portion of theouter housing shell thereby engaging a mating surface of the proximalportion of the outer housing shell with a corresponding mating surfaceof the distal portion of the outer housing shell to enclose theinstrument module in a cavity cooperatively defined by the proximal anddistal portions of the outer housing shell.
 3. The method according toclaim 2, wherein inserting the proximal end of the instrument moduleinto the proximal portion of the outer housing shell includes moving theproximal end of the instrument module through an opening defined by adistally-oriented face of the proximal portion of the outer housingshell.
 4. The method according to claim 3, further comprising moving thedistal end of the instrument module through an opening defined by aproximally-oriented face of the distal portion of the outer housingshell.
 5. The method according to claim 2, further comprising:decoupling the mating surfaces of the proximal and distal portions ofthe outer housing shell; and removing the instrument module from thecavity of the outer housing shell.
 6. The method according to claim 5,further comprising inserting the instrument module into the cavity ofthe outer housing shell subsequent to providing the outer housing shellhaving at least a sterilized outer surface such that the outer surfaceof the outer housing shell is sterile following insertion of theinstrument module into the outer housing shell.
 7. The method accordingto claim 2, further comprising forming a fluid-tight seal between theouter housing shell and a drive shaft of the instrument module.
 8. Asurgical instrument, comprising: an outer housing shell including: aproximal portion having a face, the face of the proximal portiondefining an opening therein and including a mating surface; and a distalportion having a face, the face of the distal portion defining anopening therein and including a mating surface configured to mate withthe mating surface of the proximal portion; and an instrument moduleconfigured for receipt in a cavity cooperatively defined by the proximaland distal portions of the outer housing shell, and through at least oneof the opening of the proximal portion of the outer housing shell or theopening of the distal portion of the outer housing shell.
 9. Thesurgical instrument according to claim 8, wherein the instrument moduleincludes: a proximal end configured for receipt within the proximalportion of the outer housing shell; and a distal end configured forreceipt within the distal portion of the outer housing shell.
 10. Thesurgical instrument according to claim 8, wherein the distal portion ofthe outer housing shell includes an upper portion and a lower portionextending substantially perpendicularly from the upper portion.
 11. Thesurgical instrument according to claim 8, wherein the outer housingshell has a first configuration, in which the instrument module isselectively insertable therein, and a second configuration, in which themating surfaces of the proximal and distal portions of the outer housingshell are engaged to one another.
 12. The surgical instrument accordingto claim 11, wherein in the first configuration, the face of theproximal portion of the outer housing shell is oriented distally, andthe face of the distal portion of the outer housing shell is orientedproximally.
 13. The surgical instrument according to claim 8, whereinthe instrument module includes a drive shaft disposed within the distalend of the instrument module.
 14. The surgical instrument according toclaim 13, wherein the outer housing shell includes a seal supported inthe distal portion of the outer housing shell, the seal forming afluid-tight seal between the outer housing shell and the drive shaft.15. The surgical instrument according to claim 8, wherein each of theproximal and distal portions of the outer housing shell includes anouter surface and an inner surface, wherein at least the outer surfaceof each of the proximal and distal portions of the outer housing shellis sterile.
 16. A method of assembling a surgical instrument, the methodcomprising: providing an outer housing shell including: a proximalportion having a face, the face of the proximal portion defining anopening therein and including a mating surface; and a distal portionhaving a face, the face of the distal portion defining an openingtherein and including a mating surface configured to mate with themating surface of the proximal portion; providing an instrument modulehaving a proximal end, and a distal end; inserting the proximal end ofthe instrument module into the proximal portion of the outer housingshell; and approximating the proximal portion of the outer housing shelland the distal portion of the outer housing shell thereby engaging themating surface of the proximal portion of the outer housing shell withthe mating surface of the distal portion of the outer housing shell toenclose the instrument module in a cavity cooperatively defined by theproximal and distal portions of the outer housing shell.
 17. The methodaccording to claim 16, wherein inserting the proximal end of theinstrument module into the proximal portion of the outer housing shellincludes moving the proximal end of the instrument module through theopening defined by the face of the proximal portion of the outer housingshell.
 18. The method according to claim 17, further comprising movingthe distal end of the instrument module through the opening defined bythe face of the distal portion of the outer housing shell.
 19. Themethod according to claim 16, further comprising: decoupling the matingsurfaces of the proximal and distal portions of the outer housing shell;and removing the instrument module from the cavity of the outer housingshell.
 20. The method according to claim 19, further comprisinginserting the instrument module into the cavity of the outer housingshell subsequent to providing the outer housing shell having at least asterilized outer surface such that the outer surface of the outerhousing shell is sterile following insertion of the instrument moduleinto the outer housing shell.
 21. The method according to claim 16,further comprising forming a fluid-tight seal between the outer housingshell and a drive shaft of the instrument module.